High performance water-based drilling mud and method of use

ABSTRACT

A method of forming a subterranean well and a method of reducing the swelling of shale clay during the drilling of the subterranean well. The method features the use of a water based drilling fluid, wherein the drilling fluid is formulated to include: an aqueous based continuous phase; a weight material; an optional shale hydration inhibition agent and a shale encapsulator. The shale encapsulator has the formula: 
                         
in which x and y have a value so that the molecular weight of the cation is in the range of about 10,000 to about 200,000 AMU; A is selected from C 1 -C 6  alkyl, C 2 -C 6  ether or C 2 -C 6  amide; R, R′and R″are independently selectable C 1 -C 3  alkyl; and B − is a charge balancing anion to the quaternary amine. The shale hydration inhibition agent and the shale encapsulator may be present in sufficient concentrations to reduce the swelling of the subterranean formation in the presence of water. Conventional additives may be included into the formulation of the drilling fluid, including: fluid loss control agents, alkaline reserve and other pH control agents, bridging agents, lubricants, anti-bit balling agents, corrosion inhibition agents, surfactants, solids suspending agents, and mixtures and combinations of these and other similar additives.

This application is a continuation application of U.S. Ser. No.10/654,505, filed Sep. 03, 2003, now U.S. Pat. No. 7,192,907.

BACKGROUND

In rotary drilling of subterranean wells numerous functions andcharacteristics are expected of a drilling fluid. A drilling fluidshould circulate throughout the well and carry cuttings from beneath thebit, transport the cuttings up the annulus, and allow their separationat the surface. At the same time, the drilling fluid is expected to cooland clean the drill bit, reduce friction between the drill string andthe sides of the borehole, and maintain stability in the borehole'suncased sections. The drilling fluid should also form a thin, lowpermeability filter cake that seals openings in formations penetrated bythe bit and act to reduce the unwanted influx of formation fluids frompermeable rocks, by having a controllable density to compensate forsubterreanean pressures.

Drilling fluids are typically classified according to their basematerial. In oil based fluids, solid particles are suspended inoleophilic materials (oil), and water or brine may be emulsified withinthe oil. The oil is typically the continuous phase. In water-basedfluids, solid particles are suspended in water or brine, and oil may beemulsified in the water. The water or brine is typically the continuousphase. Pneumatic fluids are a third class of drilling fluids in which ahigh velocity stream of air or natural gas aids in the removal of drillcuttings.

Three types of solids are usually found in water base drillingfluids: 1) clays and organic colloids added to provide necessaryviscosity and filtration properties; 2) heavy minerals whose function isto increase the drilling fluid's density; and 3) formation solids thatbecome dispersed in the drilling fluid during the drilling operation.

The formation solids that become dispersed in a drilling fluid aretypically from the cuttings produced by the drill bit's action and thesolids produced by borehole instability. Where the formation solids areclay minerals that swell or disperse, the presence of either type offormation solids in the drilling fluid can greatly increase drillingtime and costs.

Clay minerals are generally crystalline in nature. The structure of theclay's crystals determines its properties. Typically, clays have aflaky, mica-type structure. Clay flakes are made up of a number ofcrystal platelets stacked face-to-face. Each platelet is called a unitlayer, and the surfaces of the unit layer are called basal surfaces.

A unit layer is composed of multiple sheets. One type of sheet is calledthe octahedral sheet, it is composed of either aluminum or magnesiumatoms octahedrally coordinated with the oxygen atoms of hydroxyls.Another type of sheet is called the tetrahedral sheet. The tetrahedralsheet consists of silicon atoms tetrahedrally coordinated with oxygenatoms.

Sheets within a unit layer link together by sharing oxygen atoms. Whenthis linking occurs between one octahedral and one tetrahedral sheet,one basal surface consists of exposed oxygen atoms while the other basalsurface has exposed hydroxyls. It is also quite common for twotetrahedral sheets to bond with one octahedral sheet by sharing oxygenatoms. The resulting structure, known as the Hoffman structure, has anoctahedral sheet that is sandwiched between the two tetrahedral sheets.As a result, both basal surfaces in a Hoffman structure are composed ofexposed oxygen atoms.

The unit layers stack together face-to-face and are held in place byweak attractive forces. The distance between corresponding planes inadjacent unit layers is called the c-spacing. A clay crystal structurewith a unit layer consisting of three sheets typically has a c-spacingof about 9.5×10⁻⁷ mm.

In clay mineral crystals, atoms having different valences commonly willbe positioned within the sheets of the structure to create a negativepotential at the crystal surface. In this case, a cation is adsorbed onthe surface. These adsorbed cations are called exchangeable cationsbecause they may chemically trade places with other cations when theclay crystal is in an aqueous environment. In addition, ions may also beadsorbed on the clay crystal edges and exchange with other ions in thewater.

The type of substitutions occurring within the clay crystal structureand the exchangeable cations adsorbed on the crystal surface greatlyaffect clay swelling, a property of primary importance in the drillingfluid industry. Clay swelling is a phenomenon in which water moleculessurround a clay crystal structure and position themselves to increasethe structure's c-spacing thus resulting in an increase in volume. Twotypes of swelling may occur.

Surface hydration is one type of swelling in which water molecules areadsorbed on crystal surfaces. Hydrogen bonding holds a layer of watermolecules to the oxygen atoms exposed on the crystal surfaces.Subsequent layers of water molecules align to form a quasi-crystallinestructure between unit layers which results in an increased c-spacing.Virtually all types of clays swell in this manner.

Osmotic swelling is a second type of swelling. Where the concentrationof cations between unit layers in a clay mineral is higher than thecation concentration in the surrounding water, water is osmoticallydrawn between the unit layers and the c-spacing is increased. Osmoticswelling results in larger overall volume increases than surfacehydration. However, only certain clays, like sodium montmorillonite,swell in this manner.

Exchangeable cations found in clay minerals are reported to have asignificant impact on the amount of swelling that takes place. Theexchangeable cations compete with water molecules for the availablereactive sites in the clay structure. Generally cations with highvalences are more strongly adsorbed than cations with low valences.Thus, clays with low valence exchangeable cations will swell more thanclays whose exchangeable cations have high valences.

In the North Sea and the United States Gulf Coast, drillers commonlyencounter argillaceous sediments in which the predominant clay mineralis sodium montmorillonite (commonly called “gumbo shale”). Sodiumcations are predominately the exchangeable cations in gumbo shale. Asthe sodium cation has a low positive valence (i.e. formally a +1valence), it easily disperses into water. Consequently, gumbo shale isnotorious for its swelling.

Clay swelling during the drilling of a subterranean well can have atremendous adverse impact on drilling operations. The overall increasein bulk volume accompanying clay swelling impacts the stability of theborehole, and impedes removal of cuttings from beneath the drill bit,increases friction between the drill string and the sides of theborehole, and inhibits formation of the thin filter cake that sealsformations. Clay swelling can also create other drilling problems suchas loss of circulation or stuck pipe and increased viscosity of thedrilling fluid that slow drilling and increase drilling costs. Thus,given the frequency in which gumbo shale is encountered in drillingsubterranean wells, the development of a substance and method forreducing clay swelling remains a continuing challenge in the oil and gasexploration industry.

One method to reduce clay swelling is to use salts in drilling fluids.Salts generally reduce the swelling of clays. However, salts canflocculate the clays resulting in both high fluid losses and an almostcomplete loss of thixotropy. Further, increasing salinity oftendecreases the functional characteristics of drilling fluid additives.

Another method for controlling clay swelling is to use organic shaleinhibitor molecules in drilling fluids. It is believed that the organicshale inhibitor molecules are adsorbed on the surfaces of clays with theadded organic shale inhibitor competing with water molecules for clayreactive sites and thus serve to reduce clay swelling.

Organic shale inhibitor molecules can be cationic, anionic, or nonionic.Cationic organic shale inhibitors dissociate into organic cations andinorganic anions, while anionic organic shale inhibitors dissociate intoinorganic cations and organic anions. Nonionic organic shale inhibitormolecules do not dissociate.

It is important that the driller of subterranean wells be able tocontrol the rheological properties of drilling fluids by usingadditives, including organic shale inhibitor molecules. In the oil andgas industry today it is desirable that additives work both onshore andoffshore and in fresh and salt water environments. In addition, asdrilling operations impact plant and animal life, drilling fluidadditives should have low toxicity levels and should be easy to handleand to use to minimize the dangers of environmental pollution and harmto operators. Any drilling fluid additive should also provide desirableresults but should not inhibit the desired performance of otheradditives. The development of such additives will help the oil and gasindustry to satisfy the long felt need for superior drilling fluidadditives which act to control the swelling of the clay and drilledformations without adversely effecting the rheological properties ofdrilling fluids. The claimed subject matter addresses this need.

SUMMARY

The subject matter of the present disclosure is generally directed to awater based drilling fluid for use in subterranean wells that penetratea subterranean formation that swells and/or disperses in the presence ofwater. The drilling fluids of the present disclosure include: an aqueousbased continuous phase; a weight material; an optional shale hydrationinhibition agent; and a shale encapsulator in which the shale hydrationinhibition agent and the shale encapsulator are present in sufficientconcentrations to reduce the swelling and dispersion of the subterraneanformation in the presence of water. In the present illustrativeembodiment, the shale encapsulator has the formula:

in which x and y have a value so that the molecular weight of the cationis in the range of about 10,000 to about 200,000 AMU; A is selected fromC₁-C₆ alkyl, C₂-C₆ ether or C₂-C₆ amide; R, R′ and R″ are independentlyselectable C₁-C₃ alkyl; and B⁻ is a charge balancing anion.

In a preferred embodiment, the shale encapsulator has the formula:

in which x and y have a value so that the molecular weight of the cationis in the range of about 10,000 to about 200,000 AMU; and B⁻ is a chargebalancing anion. Preferably the B⁻ is an anion selected from the groupof halogen ion, sulfate ion, nitrate ion, formate ion, citrate ion,acetate ion, methylsulfonate ion, and mixtures of these and morepreferably B⁻ is a halogen ion. The shale encapsulator should be atleast partially soluble in the aqueous continuous phase in order for itto be effective. The optional shale hydration inhibitor is selected froma wide variety of well known shale inhibition as well as mixtures andcombinations of these and similar shale inhibiting compounds that shouldbe known to one of skill in the art. The illustrative drilling fluid iscomposed such that the aqueous based continuous phase is selected from:fresh water, sea water, brine, mixtures of water and water solubleorganic compounds as well as mixtures and combinations of these andsimilar compounds that should be known to one of skill in the art.Further the illustrative drilling fluid optionally contains a fluid losscontrol agent selected from the group consisting of organic polymers,starches, as well as mixtures and combinations of these and similarcompounds that should be known to one of skill in the art. The weightmaterial serves to increase the density of the illustrative drillingfluid and may be selected from barite, hematite, iron oxide, calciumcarbonate, magnesium carbonate, organic and inorganic salts, calciumchloride, calcium bromide, magnesium chloride, zinc halides as well asmixtures and combinations of these and similar compounds that should beknown to one of skill in the art. Finally it should be noted thatillustrative drilling fluid may contain other components that areconventional to the formulation of aqueous based drilling fluids.Examples of such components include: emulsifiers, suspension agents,viscosifying agents, fluid loss control agents, as well as mixtures andcombinations of these and similar components that should be known to oneof skill in the art.

It will also be appreciated by one of ordinary skill in the art that theclaimed subject matter includes a method of forming a subterranean wellutilizing the drilling fluids disclosed herein. One such illustrativemethod includes: drilling the subterranean well with a rotary drill bitand a drilling fluid as is substantially disclosed above. In onepreferred illustrative embodiment, the drilling fluid includes: anaqueous based continuous phase; an optional shale hydration inhibitionagent; and a shale encapsulator. The illustrative drilling fluid isformulated such that the shale hydration inhibition agent and the shaleencapsulator should be present in a ratio and in sufficientconcentrations to reduce the swelling of shale clay encountered duringthe drilling of the subterranean well. The shale encapsulator of theillustrative fluid has a formula of:

in which x and y have a value so that the molecular weight of the cationis in the range of about 10,000 to about 200,000 AMU and preferably inthe range of about 25,000 to about 150,000 AMU, A is selected from C₁-C₆alkyl, C₂-C₆ ether or C₂-C₆ amide; R, R′ and R″ are independentlyselectable C₁-C₃ alkyl; and B⁻ is a charge balancing anion. Preferablythe B⁻ is an anion selected from the group of halogen ion, sulfate ion,nitrate ion, formate ion, citrate ion, acetate ion, methylsulfonate ion,and mixtures of these and more preferably B⁻ is a halogen ion. The shaleencapsulator should be at least partially soluble in the aqueouscontinuous phase in order for it to be effective. The optional shalehydration inhibitor is selected from a wide variety of well known shaleinhibition as well as mixtures and combinations of these and similarshale inhibiting compounds that should be known to one of skill in theart.

The claimed invention also encompasses a method of reducing the swellingof shale clay encountered during the drilling of a subterranean well.Further it should be appreciated that the claimed invention includesmethods of using the disclosed fluids in the drilling of subterraneanwells as well. Additionally the disclosed fluids may be used in a methodof disposing of drilling solids in a subterranean formation in which thegrinding of the drilling solids takes place in the presence of awater-based fluid, formulated as disclosed herein. The resulting slurrymay then be injected into a subterranean formation.

These and other features of the claimed subject matter are more fullyset forth in the following description of preferred or illustrativeembodiments of the invention.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The claimed subject matter is directed to an aqueous based drillingfluid for use in drilling wells through a formation containing a shaleclay which swells in the presence of water. As the terms are usedherein, shale, clay, shale clay, and gumbo shale have been used todescribe hydrophilic rocks that may be encountered during the drillingof wells and which the drilling fluids of the claimed subject matterinhibit the swelling as described above. Generally the drilling fluid ofthe claimed subject matter includes an aqueous continuous phase; aweight material; a shale hydration inhibition agent; and a shaleencapsulating agent. As disclosed below, the drilling fluids of theclaimed subject matter may also include additional components, such asfluid loss control agents, bridging agents, lubricants, anti-bit ballingagents, corrosion inhibition agents, surfactants and suspending agentsand the like which may be added to an aqueous based drilling fluid.

The aqueous based continuous phase may generally be any water basedfluid phase that is compatible with the formulation of a drilling fluidand is compatible with the shale hydration inhibition agents disclosedherein. In one preferred embodiment, the aqueous based continuous phaseis selected from: fresh water, sea water, brine, mixtures of water andwater soluble organic compounds and mixtures thereof. The amount of theaqueous based continuous phase should be sufficient to form a waterbased drilling fluid. This amount may range from nearly 100% of thedrilling fluid to less than 30% of the drilling fluid by volume.Preferably, the aqueous based continuous phase is from about 95 to about30% by volume and preferably from about 90 to about 40% by volume of thedrilling fluid.

The drilling fluids of the claimed subject matter include a weightmaterial in order to increase the density of the fluid. The primarypurpose for such weighting materials is to increase the density of thedrilling fluid so as to prevent kick-backs and blow-outs. One of skillin the art should know and understand that the prevention of kick-backsand blow-outs is important to the safe day to day operations of adrilling rig. Thus the weight material is added to the drilling fluid ina functionally effective amount largely dependent on the nature of theformation being drilled. Weight materials suitable for use in theformulation of the drilling fluids of the claimed subject matter may begenerally selected from any type of weighting materials be it in solid,particulate form, suspended in solution, dissolved in the aqueous phaseas part of the preparation process or added afterward during drilling.It is preferred that the weight material be selected from the groupincluding barite, hematite, iron oxide, calcium carbonate, magnesiumcarbonate, organic and inorganic salts, and mixtures and combinations ofthese compounds and similar such weight materials that may be utilizedin the formulation of drilling fluids.

A shale hydration inhibition agent is optionally included in theformulation of the drilling fluids of the claimed subject matter so thatthe hydration of shale and shale like formations is inhibited. Thus, theshale hydration inhibition agent should be present in sufficientconcentration to reduce either or both the surface hydration basedswelling and/or the osmotic based swelling of the shale clay. The exactamount of the shale hydration inhibition agent present in a particulardrilling fluid formulation can be determined by a trial and error methodof testing the combination of drilling fluid and shale clay formationencountered. Generally however, the shale hydration inhibition agent ofthe claimed subject matter may be used in drilling fluids in aconcentration from about 1 to about 18 pounds per barrel (lbs/bbl orppb) and more preferably in a concentration from about 2 to about 12pounds per barrel of drilling fluid. Illustrative shale inhibitionagents may be selected from such compounds that are well known to one ofskill in the art as well as combinations of these and similar compoundsthat should be know to one of skill in the art.

A shale encapsulator is included in the formulation of the aqueous baseddrilling fluids of the claimed subject matter. The role of the shaleencapsulator is to encapsulate, i.e. coat or cover on a molecular level,the surface of the drilled shale solids and thus at least partiallyinhibit swelling and/or dispersion or aid in the action of conventionalshale inhibitors. This is accomplished by creating a molecule that has apolymeric backbone made of hydrocarbon, such as poly-ethylene on towhich polar organic pendent groups are attached. While not intending tobe bound by any specific theory of action, it is believed that thiscombination of molecular structure results in the strong adherence ofthe shale encapsulator to the shale drilling solid's surface, by way ofthe polar organic group. As a result, the drilled shale solids isencapsulated in a molecular polymer coating that enhances the action ofthe shale inhibitor and thus prevents water molecules from swelling theshale and mechanical action from dispersing the shale. Alternatively ithas been speculated that the shale encapsulating compounds formmolecular cross-links between the shale/clay mineral crystals, thuseffectively locking their relative position. By doing so, water is lessable to penetrate the spaces between the mineral crystals and thusswelling and/or dispersion of the shale is inhibited. Regardless of theactual theory of action, the shale encapsulators of the claimed subjectmatter have a generalized molecular structure of:

in which x and y have a value so that the molecular weight of the cationis in the range of about 10,000 to about 200,000 AMU and preferably inthe range of about 25,000 to about 150,000 AMU, A is selected from C₁-C₆alkyl, C₂-C₆ ether or C₂-C₆ amide; R, R′ and R″ are independentlyselectable C₁-C₃ alkyl; and B⁻ is a charge balancing anion.

In a preferred and illustrative embodiment, the molecular structure hasthe formula:

in which x and y have a value so that the molecular weight of the cationis in the range of about 10,000 to about 200,000 AMU; and B⁻ is an anionselected to counterbalance the positive charge of the quaternary amine.Suitable examples of anions that are useful include halogen ion, sulfateion, nitrate ion, formate ion, citrate ion, acetate ion, methylsulfonateion, as well as combinations of these and other similar compounds thatshould be well known to one of skill in the art. The application ofpolyvinyl alcohol (PVA) derivatives such as those indicated above arebelieved to be known as shale inhibitors or encapsulators. The use ofPVA in combination with the potassium ion is reported in the literature,however, the toxicity of the potassium ion limits its application incertain areas of the world and PVA alone is ineffective in preventingshale hydration. The synthesis of such compounds are well known based onthe copolymerization of amine based monomers and vinyl acetate toproduce amine or quaternized amine derivatives of PVA. One of skill inthe art should also appreciate that PVA can be reacted withacrylonitrile and the subsequent product hydrogenated to produce aminebased PVA. By varying the molecular weight and degree of amination, awide variety of products with a corresponding spectrum of shaleinhibiting properties will be produced. By systematically doing this,one of skill will be able to create shale encapsulators for use in lowsalinity (including fresh water) or low conductivity aqueous baseddrilling fluids which in the past have been the most difficult tocontrol shale swelling and/or dispersion.

In addition to the components noted above, the claimed drilling fluidsmay also be formulated to include materials generically referred to asgelling materials, thinners, and fluid loss control agents, as well asother compounds and materials which are optionally added to water basedrilling fluid formulations. Of these additional materials, each can beadded to the formulation in a concentration as rheologically andfunctionally required by drilling conditions. Typical gelling materialsused in aqueous based drilling fluids are bentonite, sepiolite, clay,attapulgite clay, anionic high-molecular weight polymers andbiopolymers.

Thinners such as lignosulfonates are also often added to water-basedrilling fluids. Typically lignosulfonates, modified lignosulfonates,polyphosphates and tannins are added. In other embodiments, lowmolecular weight polyacrylates can also be added as thinners. Thinnersare added to a drilling fluid to reduce flow resistance and controlgelation tendencies. Other functions performed by thinners includereducing filtration and filter cake thickness, counteracting the effectsof salts, minimizing the effects of water on the formations drilled,emulsifying oil in water, and stabilizing mud properties at elevatedtemperatures.

A variety of fluid loss control agents may be added to the drillingfluids of the claimed subject matter that are generally selected from agroup consisting of synthetic organic polymers, biopolymers, andmixtures thereof. Fluid loss control agents such as modified lignite,polymers, starches, modified starches and modified celluloses may alsobe added to the water base drilling fluid system of this invention. Inone embodiment it is preferred that the additives of the inventionshould be selected to have low toxicity and to be compatible with commonanionic drilling fluid additives such as polyanioniccarboxymethylcellulose (PAC or CMC), polyacrylates, lignosulfonates,xanthan gum, mixtures of these and the like.

The drilling fluid of the claimed subject matter may further contain anencapsulating agent generally selected from the group consisting ofsynthetic organic, and bio-polymers and mixtures thereof. The role ofthe encapsulating agent is to absorb at multiple points along the chainonto the clay particles, thus binding the particles together andencapsulating the cuttings. These encapsulating agents help improve theremoval of cuttings with less dispersion of the cuttings into thedrilling fluids. The encapsulating agents may be anionic, cationic,amphoteric, or non-ionic in nature.

Other additives that could be present in the drilling fluids of theclaimed subject matter include products such as lubricants, penetrationrate enhancers, defoamers, corrosion inhibitors and loss circulationproducts. Such compounds should be known to one of ordinary skill in theart of formulating aqueous based drilling fluids.

The method of use of the above-disclosed fluids as drilling fluids iscontemplated as being within the scope of the claimed subject matter.Such use would be conventional to the art of drilling subterranean wellsand one having skill in the art should appreciate such processes andapplications. The use of the above fluids in the slurification anddisposal of drilling cuttings containing swellable shale clays is alsocontemplated. It is also contemplated that these fluids may be used in awide variety of subterranean well operations in which the prevention ofthe swelling of gumbo shale clays and other similar formations isdesired. Such uses include use as a packing fluid, fracturing fluid,reworking fluid, well bore recompletion fluid and the like where theproperties of the fluid will be useful.

The following examples are included to demonstrate preferred embodimentsof the invention. It should be appreciated by those of skill in the artthat the techniques disclosed in the examples which follow representtechniques discovered by the inventors to function well in the practiceof the invention, and thus can be considered to constitute preferredmodes for its practice. However, those of skill in the art should, inlight of the present disclosure, appreciate that many changes can bemade in the specific embodiments which are disclosed and still obtain alike or similar result without departing from the scope of theinvention.

Unless otherwise stated, all starting materials are commerciallyavailable and standard laboratory techniques and equipment are utilized.The tests were conducted in accordance with the procedures in APIBulletin RP 13B-2, 1990. The following abbreviations are sometimes usedin describing the results discussed in the examples:

-   -   “PV” is plastic viscosity (CPS) which is one variable used in        the calculation of viscosity characteristics of a drilling        fluid.    -   “YP” is yield point (lbs/100 ft²) which is another variable used        in the calculation of viscosity characteristics of drilling        fluids.    -   “GELS” (lbs/100 ft²) is a measure of the suspending        characteristics and the thixotropic properties of a drilling        fluid.    -   “F/L” is API fluid loss and is a measure of fluid loss in        milliliters of drilling fluid at 100 psi.    -   “Encapsulator A” is a conventional encapsulator a quaternary        polyacrylamide.    -   “PVA” is polyvinyl alcohol having a molecular weight comparable        to that of the compounds of the present invention. (i.e. 10,000        to 200,000 AMU).    -   “PVA-Quat” is a quaternized polyvinyl alcohol as disclosed        herein.

EXAMPLE 1

The following muds are formulated to illustrate the claimed subjectmatter:

A B C Fresh Water (ml) 350    350    350    Shale Inhibitor (g) 7.0 7.07.0 Biopolymer (g) 1.0 1.0 1.0 PHPA 2.0 — — (Partially hydratedpolyacryl amide) Shale Encapsulator - PVA (g) — 2.0 — ShaleEncapsulator - PVA-Quat — — 2.0 (g) Lime (g) * * * *sufficient lime wasadded to obtain a pH value of 11.5.

The properties of the above mud formulations were determined at roomtemperature after hot rolling for 16 hours at 150° F. Exemplary data isgiven in the following table:

Mud Properties at room temp. A B C Rheology at 600 rpm (cps) 59 14 17300 41 10 12 200 35 9 9 100 27 6 7  6 12 3 3  3 9 3 3 Gels  10 sec. 12 33  10 min. 14 3 3 PV 18 4 5 YP 23 6 7 pH 10.8 10.4 10.7

Upon review of the above data, one of skill in the art should appreciatethat the state of the art shale encapsulator (PHPA) has excessiveviscosity in the fluids.

Dispersion tests were run with Arne and Oxford cuttings by hot rolling10 g of cuttings in a one-barrel equivalent of mud for 16 hours at 150°F. After hot rolling the remaining cuttings were screened using a 20mesh screen and washed with 10% potassium chloride water, dried and thenweighed to obtain the percentage recovered. The results of thisevaluation are given in the following Table and shows the improved shaleinhibition performance of shale inhibition agent (I) of this invention.

(% cuttings recovered) A B C Arne 29.5 66.1 94.8 Oxford 80.8 96.9 99.3

To further demonstrate the performance of the drilling fluids formulatedin accordance with the teachings of this invention, a test using a bulkhardness tester was conducted. A BP Bulk Hardness Tester is a devicedesigned to give an assessment of the hardness of shale cuttings exposedto drilling fluids, which in turn can be related to the inhibitingproperties of the drilling fluid being evaluated. In this test, shalecutting are hot rolled in the test drilling fluid at 150° F. for 16hours. Shale cuttings are screened and then placed into a BP BulkHardness Tester. The equipment is closed and using a torque wrench theforce used to extrude the cuttings through a plate with holes in it isrecorded. Depending on the hydration state and hardness of the cuttingsand the drilling fluid used, a plateau region in torque is reached asextrusion of the cuttings begins to take place. Alternatively, thetorque may continue to rise which tends to occur with harder cuttingssamples. Therefore, the higher the torque number obtained, the moreinhibitive the drilling fluid system is considered. Illustrative dataobtained using the three different mud formulations with three differentcuttings are given below.

Bulk Hardness: (values in inch/lbs) Mud Formulation Turn No. A B C ArneClay  9 — — 10 10 — — 45 11 — 35 50 12 — 50 75 13 — 60 85 14 10 90 15015 10 150 240 Oxford Clay  6 — 10 10  7 — 20 25  8 — 40 60  9 10 210 28010 70 320 350 11 130 350 — 12 150 Disk Disk 13 180 — — 14 220 — — 15 330— —

Upon review of the above data, one skilled in the art should observethat drilling fluids formulated according to the teachings of thisinvention prevent the hydration of various types of shale clays and thusare likely to provide good performance in drilling subterranean wellsencountering such shale clays.

In view of the above disclosure, one of ordinary skill in the art shouldunderstand and appreciate that one illustrative embodiment of theclaimed subject matter includes a water based drilling fluid for use indrilling a subterranean well through a subterranean formation thatswells in the presence of water. The drilling fluid includes: an aqueousbased continuous phase; a weight material; an optional shale hydrationinhibition agent; and a shale encapsulator in which the shale hydrationinhibition agent and the shale encapsulator are present in sufficientconcentrations to reduce the swelling of the subterranean formation inthe presence of water. In the present illustrative embodiment, the shaleencapsulator has the formula:

in which x and y have a value so that the molecular weight of the cationis in the range of about 10,000 to about 200,000 AMU and preferably inthe range of about 25,000 to about 150,000 AMU, A is selected from C₁-C₆alkyl, C₂-C₆ ether or C₂-C₆ amide; R, R′ and R″ are independentlyselectable C₁-C₃ alkyl; and B⁻ is a charge balancing anion. Preferablythe B⁻ is an anion selected from the group of halogen ion, sulfate ion,nitrate ion, formate ion, citrate ion, acetate ion, methylsulfonate ionand mixtures of these and more preferably B⁻ is a halogen ion. The shalehydration inhibitor is selected from compounds well known to one ofskill in the art as well as mixtures and combinations of these andsimilar shale inhibiting compounds that should be known to one of skillin the art. The illustrative drilling fluid is composed such that theaqueous based continuous phase is selected from: fresh water, sea water,brine, mixtures of water and water soluble organic compounds as well asmixtures and combinations of these and similar compounds that should beknown to one of skill in the art. Further the illustrative drillingfluid optionally contains a fluid loss control agent selected from thegroup consisting of organic polymers, starches, as well as mixtures andcombinations of these and similar compounds that should be known to oneof skill in the art. The weight material serves to increase the densityof the illustrative drilling fluid and may be selected from barite,hematite, iron oxide, calcium carbonate, magnesium carbonate, organicand inorganic salts, calcium chloride, calcium bromide, magnesiumchloride, zinc halides as well as mixtures and combinations of these andsimilar compounds that should be known to one of skill in the art.Finally it should be noted that illustrative drilling fluid may containother components that are conventional to the formulation of aqueousbased drilling fluids. Examples of such components include: emulsifiers,suspension agents, viscosifying agents, fluid loss control agents, aswell as mixtures and combinations of these and similar components thatshould be known to one of skill in the art.

Another illustrative and preferred embodiment of the claimed subjectmatter includes a water based drilling fluid which includes: an aqueousbased continuous phase; a weight material; an optional shale hydrationinhibition agent; and a shale encapsulator having the formula:

in which x and y have a value so that the molecular weight of the cationis in the range of about 10,000 to about 200,000 AMU; and preferably inthe range of about 25,000 to about 150,000 AMU and B⁻ is a chargebalancing anion and B⁻ preferably is an anion selected from the group ofhalogen ion, sulfate ion, nitrate ion, formate ion, citrate ion, acetateion, methylsulfonate ion, and mixtures of these. The illustrativedrilling fluid is formulated such that the optional shale hydrationinhibition agent and the shale encapsulator are present in a ratio andare in sufficient concentrations to reduce the swelling of thesubterranean formation in the presence of water. In one preferredembodiment, the shale hydration inhibitor is a conventional shalehydration inhibitor known to one of skill in the art well as mixturesand combinations of these and similar shale inhibiting compounds thatshould be known to one of skill in the art. The illustrative drillingfluid is composed such that the aqueous based continuous phase isselected from: fresh water, sea water, brine, mixtures of water andwater soluble organic compounds as well as mixtures and combinations ofthese and similar compounds that should be known to one of skill in theart. Further the illustrative drilling fluid optionally contains a fluidloss control agent selected from the group consisting of organicpolymers, starches, as well as mixtures and combinations of these andsimilar compounds that should be known to one of skill in the art. Theweight material serves to increase the density of the illustrativedrilling fluid and may be selected from barite, hematite, iron oxide,calcium carbonate, magnesium carbonate, organic and inorganic salts,calcium chloride, calcium bromide, magnesium chloride, zinc halides aswell as mixtures and combinations of these and similar compounds thatshould be known to one of skill in the art. The illustrative drillingfluid further contains a fluid loss control agent selected fromcompounds including organic polymers, starches, as well as mixtures andcombinations of these and similar components that should be known to oneof skill in the art. Finally it should be noted that the illustrativedrilling fluid may contain other components that are conventional to theformulation of aqueous based drilling fluids. Examples of suchcomponents include: emulsifiers, suspension agents, viscosifying agents,as well as mixtures and combinations of these and similar componentsthat should be known to one of skill in the art.

It will also be appreciated by one of ordinary skill in the art that apresent illustrative embodiment of the claimed subject matter includes amethod of forming a subterranean well utilizing the drilling fluidsdisclosed herein. One such illustrative method includes: drilling thesubterranean well with a rotary drill bit and a drilling fluid as issubstantially disclosed above. In one preferred illustrative embodiment,the drilling fluid includes: an aqueous based continuous phase; anoptional shale hydration inhibition agent; and a shale encapsulator. Theillustrative drilling fluid is formulated such that the shale hydrationinhibition agent and the shale encapsulator may be present in a ratioand are in sufficient concentrations to reduce the swelling of shaleclay encountered during the drilling of the subterranean well. The shaleencapsulator of the illustrative fluid has a formula of:

in which x and y have a value so that the molecular weight of the cationis in the range of about 10,000 to about 200,000 AMU and preferably inthe range of about 25,000 to about 150,000 AMU, A is selected from C₁-C₆alkyl, C₂-C₆ ether or C₂-C₆ amide; R, R′ and R″ are independentlyselectable C₁-C₃ alkyl; and B⁻ is a charge balancing anion. Preferably,B⁻ is a charge balancing anion selected from the group of halogen ion,sulfate ion, nitrate ion, formate ion, citrate ion, acetate ion,methylsulfonate ion, as well as combinations of these and other similarcompounds that should be well known to one of skill in the art.

The claimed invention also encompasses a method of reducing the swellingof shale clay encountered during the drilling of a subterranean well.Such an illustrated method includes circulating in the subterranean wellan aqueous based drilling fluid that is formulated as is substantiallydescribed in the present disclosure. The illustrative aqueous baseddrilling fluid should be formulated to include: an aqueous basedcontinuous phase; an optional shale hydration inhibition agent and ashale encapsulator such that the shale hydration inhibition agent andthe shale encapsulator may be present in a ratio and in sufficientconcentrations to reduce the swelling of the subterranean formation inthe presence of water.

The shale encapsulator utilized in the illustrative drilling fluid mayhave the formula:

in which x and y have a value so that the molecular weight of the cationis in the range of about 10,000 to about 200,000 AMU and preferably inthe range of about 25,000 to about 150,000 AMU, A is selected from C₁-C₆alkyl, C₂-C₆ ether or C₂-C₆ amide; R, R′ and R″ are independentlyselectable C₁-C₃ alkyl; and B⁻ is a charge balancing anion, preferablyselected from the group of halogen ion, sulfate ion, nitrate ion,formate ion, citrate ion, acetate ion, methylsulfonate ion, as well asmixtures and combinations which should be known to one of skill in theart.

Further it should be appreciated that the claimed invention includes amethod of disposing of drilling solids in a subterranean formation. Insuch an illustrative embodiment, the method includes; grinding thedrilling solids in a water-based fluid, formulated as disclosed herein,to form a slurry, and injecting said slurry into the subterraneanformation. The water based fluid utilized in the illustrative embodimentincludes: an aqueous based continuous phase, a shale hydrationinhibition agent; and a shale encapsulator having the formula:

in which x and y have a value so that the molecular weight of the cationis in the range of about 10,000 to about 200,000 AMU and preferably inthe range of about 25,000 to about 150,000 AMU, A is selected from C₁-C₆alkyl, C₂-C₆ ether or C₂-C₆ amide; R, R′ and R″ are independentlyselectable C₁-C₃ alkyl; and B⁻ is a charge balancing anion, preferablyselected from the group of halogen ion, sulfate ion, nitrate ion,formate ion, citrate ion, acetate ion, methylsulfonate ion, and mixturesof these and similar compounds that should be well known to one of skillin the art.

While the apparatus, compositions, and methods disclosed above have beendescribed in terms of preferred or illustrative embodiments, it will beapparent to those of skill in the art that variations may be applied tothe process described herein without departing from the concept andscope of the claimed subject matter. All such similar substitutes andmodifications apparent to those skilled in the art are deemed to bewithin the scope and concept of the subject matter as it is set out inthe following claims.

1. A method of forming a subterranean well, the method comprisingdrilling the subterranean well with a rotary drill bit and a drillingfluid; said drilling fluid including: an aqueous based continuous phase;an optional shale hydration inhibition agent; and a shale encapsulatorhaving the formula:

in which x and y have a value so that the molecular weight of the cationis in the range of about 10,000 to about 200,000 AMU; A is selected fromC₁-C₆ alkyl, C₂-C₆ ether or C₂C₆amide; R, R′ and R″ are independentlyselectable C₁-C₃ alkyl; and wherein B⁻ is an anion selected from thegroup of halogen ion, sulfate ion, nitrate ion, formate ion, citrateion, acetate ion, methylsulfonate ion, and mixtures of these; andwherein the shale hydration inhibition agent and the shale encapsulatorare present in a ratio and are in a sufficient concentrations to reducethe swelling of shale clay encountered during the drilling of thesubterranean well.
 2. A method of reducing the swelling of shale clayencountered during the drilling of a subterranean well, the methodcomprising: circulating in the subterranean well an aqueous baseddrilling fluid including: an aqueous based continuous phase; a shalehydration inhibition agent; and a shale encapsulator having the formula:

in which x and y have a value so that the molecular weight of the cationis in the range of about 10,000 to about 200,000 AMU; A is selected fromC₁-C₆ alkyl, C₂-C₆ ether or C₂-C₆amide; R, R' and R″ are independentlyselectable C₁-C₃ alkyl; and wherein B³¹ is an anion selected from thegroup of halogen ion, sulfate ion, nitrate ion, formate ion, citrateion, acetate ion, methylsulfonate ion, and mixtures of these; andwherein the shale hydration inhibition agent and the shale encapsulatorare present in a ratio and are in sufficient concentrations to reducethe swelling of the subterranean formation in the presence of water.